Radiator, removing and installing

WARNING: This page is about a different car, the 2008 Audi RS 4 and 2007 Audi RS 4. However, it is still accessible from the selected car via links, so may be relevant.

Special tools, testers and auxiliary items required

Fig 1: Drip Tray For VAS 6100, VAS 6208

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Drip tray for workshop crane VAS 6208

Removing

NOTE:

Drained coolant must be stored in a clean container for disposal or reuse.

CAUTION: Cover cap of coolant expansion tank with rag and open carefully, as hot steam or hot coolant may escape when opening.

Open cap of coolant expansion tank.

Fig 2: Removing Quick-Release Fasteners, Screws And Noise Insulation

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove quick-release fasteners - 1 - , remove screws - 2 - and remove noise insulation.
Remove front bumper cover →
- 63 BUMPER
- 63 - BUMPERS for BODY EXTERIOR - CABRIOLET
.

Fig 3: Disconnecting Left/Right Electrical Connectors Of Horns

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical connector - 3 -.

NOTE:

Ignore - 1 - and - 2 -.

Fig 4: Disconnecting Electrical Harness Connectors & Removing Bolts At Bumper Impact Absorber

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical harness connectors - 1 to 3 -.
Remove bolts - arrows - at bumper impact absorber.
Remove impact absorber.

Fig 5: Removing Right Air Guide In Front Of Auxiliary Cooler

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove right air guide - arrow - in front of auxiliary cooler.

Fig 6: Removing Left Air Guide In Front Of Auxiliary Cooler

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove left air guide - arrow - in front of auxiliary cooler.

Fig 7: Removing Drain Plug On Coolant Thermostat Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place drip tray for workshop crane VAS 6208 under engine.
Remove drain plug - arrow - on coolant thermostat housing and drain coolant from engine.

Fig 8: Removing Coolant Hose Downward From Cooler

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect lower coolant hose from radiator - arrow - and drain residual coolant.

Fig 9: Removing Bolts & Air Ducts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - arrows -.
Remove air duct - 1 - and - 2 -.

Fig 10: Disconnecting Top Coolant Hose From Radiator

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect top coolant hose - arrow - from radiator.

Fig 11: Removing Right Coolant Hose

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove right auxiliary cooler coolant hose - arrow - at cooler.

Fig 12: Removing Bolts On Left/Right Air Guides At Cooler

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - arrows - on left and right air guides at cooler.

Fig 13: Removing Oil Cooler Nuts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove nuts - 1 to 5 -.
Lay oil cooler with power steering cooler with connected lines forward.

CAUTION: The air conditioning refrigerant circuit must not be opened.

NOTE:

To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.

Fig 14: Disconnecting Electrical Harness Connector At High Pressure Sensor G65

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical harness connector - 1 - at High Pressure Sensor G65.
Remove bolts - arrows -.
Remove condenser and lay forward with connected lines.

Fig 15: Releasing Both Radiator Retaining Pins And Removing By Pulling Upward

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Release both radiator retaining pins and remove by pulling upward - arrows -.
Tilt radiator at upper edge forward, pull up and remove.

Installing

Installation is in reverse order of removal, note the following:

Install bumper impact absorber →
- 63 BUMPER
- 63 - BUMPERS for BODY EXTERIOR - CABRIOLET
.
Install front bumper cover →
- 63 BUMPER
- 63 - BUMPERS for BODY EXTERIOR - CABRIOLET
.
Fill with coolant Filling .

NOTE:

Complete coolant must be replaced if the radiator was replaced.

Torque specifications

Component	Nm
Condenser to radiator	9
Oil cooler to lock carrier	9
Power steering cooler to lock carrier	9